Chrysler Front Wheel Drive Cars 4-CYL 1981-1995 Repair Information

Oil Pump

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REMOVAL




CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

2.2L and 2.5L Except Premier Engines

See Figures 1, 2 and 3

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Fig. Fig. 1: After removing the distributor, if equipped, make sure that the oil pump shaft groove is positioned as shown



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Fig. Fig. 2: If the timing belt cover is removed, make certain that the crankshaft and intermediate shaft timing marks are aligned



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Fig. Fig. 3: Remove the oil pump retaining bolts, then remove the pump from the engine

Many of the following steps pertain to engines with a distributor. Disregard these steps when working on Turbo III engine. Since that engine does not have a distributor, the oil pump can be installed without timing the distributor gear. The oil pump on all other engines must be properly timed.

  1. Position the engine so that the No. 1 piston is at TDC of its compression stroke, as follows:
    1. Remove the upper timing belt cover.
    2.  
    3. Turn the engine until the timing marks on the flywheel are aligned with the timing mark on the transaxle housing, and the timing mark on the camshaft sprocket is aligned with the timing mark on the cylinder head; this will position the engine so that the No. 1 piston is at TDC of its compression stroke.
    4.  

  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. If equipped, remove the distributor, as described in Engine Electrical . Look down the distributor mounting hole and make sure that the oil pump shaft groove is parallel to the centerline of the engine block (crankshaft axis).
  6.  
  7. Remove the engine oil dipstick.
  8.  
  9. Apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
  10.  
  11. Drain the engine oil. For more information, refer to Routine Maintenance .
  12.  
  13. Remove the oil pan, as described earlier in this section.
  14.  
  15. Remove the oil pick-up by removing the screw on the pump cover holding the oil pick-up tube to the oil pump.
  16.  
  17. Remove the 2 mounting bolts, then remove the oil pump from the engine.
  18.  

2.5L Premier Engine

See Figure 4

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Fig. Fig. 4: Exploded view of the oil pump on 2.5L Premier engines

The 2.5L Premier engine is only found in the Premier models; all other 2.5L engines were manufactured by Chrysler.

The positive-displacement gear-type oil pump is driven by the distributor shaft, which is driven by a gear on the camshaft. Oil is siphoned into the pump through an inlet tube and strainer assembly that is pressed into the pump body. The pump incorporates a non-adjustable pressure relief valve to limit maximum pressure to 75 psi (517 kPa). In the relief position, the valve permits oil to bypass through a passage in the pump body to the inlet side of the pump.

Oil pump removal or replacement will not affect distributor timing because the distributor drive gear remains in mesh with the camshaft gear.

  1. Remove the oil pan, as described earlier in this section.
  2.  
  3. Remove the oil pump-to-engine block attaching bolts, then remove the pump assembly with the old gasket.
  4.  


WARNING
If the oil pump is not to be serviced, do not disturb position of the oil inlet tube and strainer assembly in the pump body. If the tube is moved within the pump body, a replacement tube and strainer assembly must be installed to assure an airtight seal.

2.6L Engine

For the removal and installation of the oil pump for these engines, refer to the auxiliary (silent shafts) procedure later in this section.

INSPECTION



2.2L and 2.5L Except Premier Engines

See Figures 5 through 8

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Fig. Fig. 5: Check the rotor end clearance with a straightedge and a feeler gauge as shown



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Fig. Fig. 6: Inspect inner rotor-to-outer rotor clearance as shown



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Fig. Fig. 7: Use a feeler gauge to measure the outer rotor-to-pump body clearance



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Fig. Fig. 8: The spring cup, spring and relief valve are held in the pump housing by a cotter pin-make certain to clean all components before reassembly

  1. Inspect rotor end clearance with a feeler gauge. Place straightedge across the ends of the gears and the rotors. Select a feeler gauge that fits snugly, but freely between the straightedge and the pump body. Correct clearance is 0.0010-0.0035 in. (0.03-0.09mm).
  2.  
  3. With both gears in position, measure the inner rotor-to-outer rotor clearance by inserting a feeler gauge between the gear tooth and the pump outer rotor inner wall directly opposite the point of gear mesh. Select a feeler gauge which fits snugly, but freely. Rotate the gears to measure each tooth-to-body clearance in this manner.
  4.  
  5. Correct clearance is 0.008 in. (0.20mm) maximum.
  6.  
  7. Insert a feeler gauge between the outer rotor and the oil pump housing. Select a feeler gauge which fits snugly, but freely. Rotate the gears to measure each tooth-to-body clearance in this manner.
  8.  
  9. Correct clearance is 0.014 in. (0.35mm) maximum.
  10.  
  11. Inspect the oil pump cover for flatness by placing a straightedge on the underside of the pump cover. Use feeler gauges to determine if the cover is warped or not. The maximum amount of warpage allowed is 0.003 in. (0.076mm).
  12.  
  13. If the rotor end clearance or gear-to-body clearance is more than specified, replace the oil pump assembly.
  14.  
  15. Inspect the oil pressure relief valve spring as follows:
    1. Remove the cotter pin from the relief valve spring housing.
    2.  
    3. Slide the cup, spring and relief valve out of the housing.
    4.  
    5. Clean the relief valve, spring and cup with a suitable solvent.
    6.  
    7. Measure the oil pressure relief valve spring free-length. The free length should be 1.95 in. (49.5mm).
    8.  
    9. If the free-length is not the specified length, replace the spring.
    10.  
    11. Install the relief valve, spring and cup into the pump housing, then install a new cotter pin.
    12.  

  16.  

2.5L Premier Engine

The 2.5L Premier engine is only found in the Premier models; all other 2.5L engines were manufactured by Chrysler.

GEAR END CLEARANCE

See Figures 9 and 10



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Fig. Fig. 9: When checking the gear end clearance with Plastigage®, position the strips on the gears as shown



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Fig. Fig. 10: The alternate method of inspecting gear end clearance is by using a straightedge and feeler gauges

  1. Remove the cover retaining bolts and the cover from the pump body.
  2.  
  3. The preferred method for measuring end clearance is as follows:
    1. Place a strip of Plastigage® across the full width of each gear.
    2.  
    3. Install the pump cover and tighten the retaining bolts to 70 inch lbs. (8 Nm).
    4.  
    5. Remove the pump body and determine the amount of clearance by measuring the width of the compressed Plastigage® with the scale on the Plastigage® envelope.
    6.  
    7. Correct clearance by this method is 0.002-0.006 in. (0.051-0.152mm) with 0.002 in. (0.051mm) preferred.
    8.  

  4.  
  5. An alternate method to measure gear end clearance is as follows:
    1. Place straightedge across the ends of the gears and the pump body.
    2.  
    3. Select a feeler gauge that fits snugly, but freely between the straightedge and the pump body.
    4.  
    5. Correct clearance by this method is also 0.002-0.006 in. (0.051-0.152mm) with 0.002 in. (0.051mm) preferred.
    6.  

  6.  
  7. If gear end clearance is excessive, replace the oil pump assembly.
  8.  

GEAR-TO-BODY CLEARANCE

See Figure 11

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Fig. Fig. 11: Use a feeler gauge to measure the gear-to-body clearance

  1. Remove the cover retaining bolts and the cover from the pump body.
  2.  
  3. With both gears in position, measure the gear-to-body clearance by inserting a feeler gauge between the gear tooth and the pump body inner wall directly opposite the point of gear mesh. Select a feeler gauge which fits snugly, but freely. Rotate the gears to measure each tooth-to-body clearance in this manner.
  4.  
  5. Correct clearance is 0.002-0.004 in. (0.051-0.102mm) with 0.002 in. (0.051mm) preferred.
  6.  
  7. If the gear-to-body clearance is more than specified, replace the oil pump assembly.
  8.  

OIL PUMP ASSEMBLY

See Figure 12

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Fig. Fig. 12: The special tool J-21882 should be used to install the inlet tube into the housing hole

  1. Remove the cotter pin and slide the spring retainer, spring and oil pressure relief valve plunger out of the pump body. Inspect for a binding condition during disassembly. Clean or replace, as necessary.
  2.  

The oil inlet tube and strainer assembly must be moved to allow removal of the relief valve. Install a replacement inlet tube and strainer assembly.

  1. Two relief valve plunger sizes (standard and oversize) are available. When replacing the valve, assure correct replacement valve, standard size or 0.010 in. (0.254mm) oversized plunger diameter, is obtained and installed.
  2.  
  3. Install the oil pressure relief valve plunger, spring, retainer and cotter pin.
  4.  
  5. If the position of the inlet tube in the pump body was disturbed, install a replacement inlet tube and strainer assembly. Apply a light film of Permatex® No. 2 sealant, or equivalent, around the end of the tube. Use Tool 7624 to drive the inlet tube into the body. Ensure that the support bracket is properly aligned.
  6.  
  7. Install the idler gear and drive gear assembly.
  8.  
  9. Spin the drive gear shaft to assure a binding condition does not exist before installing the oil pump.
  10.  
  11. To assure self-priming of the oil pump, fill the pump with petroleum jelly before installing the oil pump cover; Do NOT use grease.
  12.  
  13. Apply a thin bead of Loctite® 515, or equivalent, to the top of the pump housing and install the pump cover bolts to 70 inch lbs. (8 Nm).
  14.  

2.6L Engine

See Figures 13 through 17

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Fig. Fig. 13: Use feeler gauge to measure the driven gear-to-pump housing clearance, as shown



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Fig. Fig. 14: Also measure the clearance of the drive gear to the pump housing-the clearance should be 0.0043-0.0059 in. (0.11-0.15mm)



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Fig. Fig. 15: Use a straightedge and feeler gauges to measure the driven (shown) and drive gear (similar) end-play



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Fig. Fig. 16: Unlike the 2.2L and 2.5L Except Premier engines, the relief valve spring on 2.6L engines is held into the pump housing by a screw-in plug



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Fig. Fig. 17: Before installing the oil pump, make certain that the mating marks on the 2 gears are aligned as shown

  1. Inspect drive gear and driven gear end clearance with a feeler gauge. Place straightedge across the ends of the gears and the pump body. Select a feeler gauge that fits snugly, but freely between the straightedge and the drive gear. Correct clearance is 0.0020-0.0043 in. (0.05-0.11mm). Select a feeler gauge that fits snugly, but freely between the straightedge and the driven gear. Correct clearance is 0.0016-0.0039 in. (0.04-0.10mm).
  2.  
  3. With both gears in position, measure the driven gear-to-body clearance by inserting a feeler gauge between the driven gear tooth and the pump body inner wall directly opposite the point of gear mesh. Select a feeler gauge which fits snugly, but freely. Rotate the gears to measure each driven gear tooth-to-body clearance in this manner. Correct clearance is 0.0043-0.0059 in. (0.11-0.15mm) maximum.
  4.  
  5. With both gears in position, measure the drive gear-to-body clearance by inserting a feeler gauge between the drive gear tooth and the pump body inner wall directly opposite the point of gear mesh. Select a feeler gauge which fits snugly, but freely. Rotate the gears to measure each drive gear tooth-to-body clearance in this manner. Correct clearance is 0.0043-0.0059 in. (0.11-0.15mm) maximum.
  6.  
  7. If the rotor end clearance or gear-to-body clearance is more than specified, replace the oil pump assembly.
  8.  
  9. Inspect the oil pressure relief valve spring as follows:
    1. Remove the spring hole plug.
    2.  
    3. Slide the spring and relief valve out of the housing.
    4.  
    5. Clean the relief valve and spring with a suitable solvent.
    6.  
    7. Measure the oil pressure relief valve spring free-length. The free length should be 1.850 in. (47mm).
    8.  
    9. If the free-length is not the specified length, replace the spring.
    10.  
    11. Install the relief valve and spring into the pump housing, then install the spring hole plug.
    12.  

  10.  
  11. Align the drive and drive gear mating marks as shown.
  12.  
  13. Fill the oil pump assembly with 0.34 fl. oz. (10cc) of clean engine oil before installing it onto the engine.
  14.  

INSTALLATION



2.2L and 2.5L Except Premier Engines
  1. Prime the pump by pouring fresh oil into the pump intake and turning the driveshaft until oil comes out the pressure port. Repeat a few times until no air bubbles are present.
  2.  
  3. Apply Loctite® 515, or equivalent, to the pump body-to-block machined surface.
  4.  
  5. Lubricate the oil pump and distributor driveshaft with clean engine oil.
  6.  
  7. Align the slot so it will be in the same position as when it was removed (parallel to the engine centerline). If it is not, the distributor will not be timed correctly.
  8.  
  9. Slide the oil pump shaft into the engine hole, push the pump against the engine block fully while rotating the pump back and forth to ensure proper positioning between the pump mounting surface and the machined surface of the block.
  10.  
  11. Install the mounting bolts finger-tight.
  12.  
  13. From above the engine, look down the distributor mounting hole to ensure that the oil pump shaft groove is properly positioned. If the slot is not properly positioned, raise the vehicle and move the gear as required. If the slot is correct, hold the pump firmly against the block and tighten the mounting bolts to 17 ft. lbs. (23 Nm).
  14.  
  15. Clean out the oil pick-up or replace it, as required. Install the oil pick-up O-ring, then install the pick-up to the pump.
  16.  
  17. Install the oil pan, as described earlier in this section.
  18.  
  19. Install the distributor. For more information, refer to Engine Electrical .
  20.  
  21. Install the engine oil dipstick.
  22.  
  23. Fill the engine with the proper amount and type of clean, fresh engine oil, as described in Routine Maintenance .
  24.  
  25. Connect the negative battery cable, start the engine, check the timing and check the oil pressure.
  26.  

2.5L Premier Engine
  1. Install the oil pump on the engine block along with a replacement gasket. Tighten the short bolt to 125 inch lbs. (14 Nm) and the long bolt to 17 ft. lbs. (23 Nm).
  2.  
  3. Install the oil pan, as outlined earlier in this section.
  4.  
  5. Fill the engine with clean, fresh engine oil. For more information, refer to Routine Maintenance .
  6.  

2.6L Engine
  1. Position the oil pump against the engine block and install the mounting = fasteners. Tighten the bolts to 71 inch lbs. (8 Nm).
  2.  
  3. Install the oil pump sprocket, timing chains, timing chain cover and a new front cover oil seal. For more information, refer to the timing chain cover and seal and timing chain removal and installation procedures later in this section.
  4.  

 
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